1 Plugging of boiler tubes

In the unlikely event of a furnace tube failing it should be repaired at once

by cutting out the affected section and welding in a new section or by
welding in a temporary insert.
However, if this is not possible the tube can be plugged as described in this
section, but it should be treated as a temporary measure only, the tube
being renewed with a minimum of delay.
When tubes are plugged in the furnace they should be renewed at the
earliest possible opportunity because of the need for adequate protection of
the furnace wall.

Note: If a furnace tube fails, the boiler load must be restricted to 75%
of full power.

There are four locations where plugging of boiler tubes can be relevant.
These locations are shown in Figure 1 and marked as location A, B, C and
D respectively. The plugging locations are divide into two categories:
• Plugging of furnace tubes (section 1.1).
• Plugging of convection tubes (section Error! Reference source not
found.).

Tube plugging locations

Figure 1 plug1.cdr

Furthermore two types of plugs are used for plugging the tubes, an internal
plug and an external plug. Both these types are shown in Figure 2. The
internal plugs are used in the intermediate and upper drum at location B, C
and D in Figure 1, and the external plugs are used in the furnace circular
header at location A.

Sketch of plugs types (internal and external plug)

Nut M20

30
Bolt M12

Packing Ring Gasket

Tube stub

Figure 2 plug4.cdr

1.1 Plugging furnace tubes

Plugging of the furnace tubes can be performed where the tubes are
connected to the furnace circular header (location A in Figure 1) and where
the furnace tubes are connected to the intermediate drum (location B in
Figure 1).
Plugging of the furnace tubes are described in section 1.1.1 and 1.1.2
respectively. The instructions for applying the refractory where tubes have
been cut away and plugged are described in section 1.1.3.
1.1.1 Plugging of furnace tubes at circular header
The procedure for cutting out a damaged tube piece and plugging the tube
at the circular header (location A in Figure 1), is shown in Figure 3 and
described in the following.
At this location an external plug is used.
Plugging of furnace tubes at circular header

Y-anchors

ø14 mm hole

Min 75 mm

Figure 3 plug2.cdr

Step A: Remove the refractory, if necessary, local to the tube being

plugged at the furnace circular header (see Figure 3, section B-B).
Step B: Cut the tube as shown in Figure 3 on the furnace side of the failed
tube. The tube should be cut approx. 110-120 mm above the
conical transition piece.
When the tube is cut, the casing close to the furnace tubes, is to be
observed.

Important: No holes must be burnt in the casing as this cannot be

repaired without removing the outside insulation.

At the top of the furnace the tube is to be cut as described in the following
section 1.1.2.
If the damaged tube is one of the tubes forming the burner opening, only
the visible part of the tube is to be removed.
Step C: Clean out any swarf, etc. from the circular header with a vacuum
cleaner.
Step D: The tube end is to be cleaned inside with emery cloth at a depth of
approx. 125 mm, before the external plug is fastened.
Step E: Drill a 14 mm hole in tube wall facing the furnace for fastening
the M12 bolt (see Figure 8). The hole is drilled 30 mm from the
end of the tube as shown in Figure 9.
 Step F: Arrange the plug as shown in Figure 2.
Step G: Fasten the M12 bolt by your fingers only.
Step H: Fasten the M20 nut tight with a spanner.
Step I: Secure the M12 bolt by using a spanner.
1.1.2 Plugging of furnace tubes at intermediate drum
The procedure for cutting out a damage tube piece and plugging the
furnace tube at location B in Figure 1, is shown in Figure 4 and described
in the following.
Here the internal plug is used.

Plugging of furnace tubes at intermediate drum

Fig 1.
B C
Fig 2.
A
VIEW A-A

CUT LINE
INSULATION

TUBE TO BE CUT AWAY

A
CASING

TUBE AND FINS TO BE CUT AWAY

INTERNAL PLUG

FURNACE TUBE

TUBE PLATE, FURNACE ROM

25

REFRACTORY LINING DETAIL C

15

DETAIL B
Figure 4 plug5.cdr

Step A: The tube is cut approx. 15 mm below the lining, without damaging
this. If the tube is going direct into the tube plate (one of the outer
tubes) then cut the tube approx. 25 mm below the tube plate
without damaging this.
 When one of these outer tubes is removed, the insulation between furnace
and casing will be unprotected. This insulation is to be removed, and a
refractory lining is to be made to protect the casing (see section 1.1.3).
When the damaged tube has been removed then:
Step B: Clean the inside surface of the tube as mentioned in section 1.1.1.
Step C: The internal plug, (Figure 2), is to be secured by hammer strokes.
1.1.3 Applying refractory
When a furnace tube has been removed, the casing and the remaining piece
of the tube are to be protected with refractory. The refractory should be
Plicast 31.
Figure 5 shows how to apply refractory where the damaged tube piece has
been removed.

Applying refractory at furnace tubes

2 OFF WALL TIE (LONG)
Fig 1.
A
Fig 3.
Fig 2.
B B
INSULATION

PLICAST 31
INSULATING PLICAST 31

C C CASTING
CASING

Fig 4.

7 OFF WALL TIE (SHORT)

VIEW B-B

PLICAST 31

A Fig 5.

VIEW A-A VIEW C-C

Figure 5 plug6.cdr

Step A: Before applying the refractory wall ties have to be welded onto the
remaining tube piece, as shown in Figure 5 fig. 2 and fig. 3.
Step B: Refractory, Plicast 31, is attached to the furnace wall, see Figure 5.
Step C: Refractory lining at one of the bent furnace tubes is to be
performed as shown in Figure 5, fig. 2. The lining should reach
somewhat above the fins of the straight tubes.
Step D: Refractory lining at one of the straight furnace tubes is to be
performed as shown in Figure 5, fig. 3. The part of the insulation
which is not protected by fins and furnace tubes is to be removed
as shown on fig. 4.
Step E: At the furnace circular header, the remaining piece of tube and
tube plug are to be protected, and the lining is carried out as
shown in Figure 5, fig. 1 and 2.

Note: The instructions for handling the refractory should be followed

carefully.